Aerosol Generating Articles and Methods for Manufacturing the Same

Abstract

A method for manufacturing an aerosol generating article includes: (i) providing a first material containing a plant-based aerosol generating material; (ii) arranging a second material, constituting a mouthpiece, in line with the first material; and (iii) wrapping the first and second materials with a sheet to form a substantially cylindrical aerosol generating article. Step (i) includes: (a) providing the plant-based aerosol generating material as a foam material; or (b) providing a cylindrical cup and filling the cylindrical cup with the plant-based aerosol generating material and a third material.

1 . A method for manufacturing an aerosol generating article, the method comprising:
 (i) providing a first material containing a plant-based aerosol generating material;   (ii) arranging a second material, constituting a mouthpiece, in line with the first material;   (iii) wrapping the first and second materials with a sheet to form a substantially cylindrical aerosol generating article;   
       wherein step (i) comprises:
 (a) providing the plant-based aerosol generating material as a foam material; or 
 (b) providing a cylindrical cup and filling the cylindrical cup with the plant-based aerosol generating material and a third material. 
 
     
     
         2 . The method according to  claim 1 , wherein the cylindrical cup is a paper cup. 
     
     
         3 . The method according to  claim 1 , wherein a bottom wall of the cylindrical cup is air-permeable. 
     
     
         4 . The method according to  claim 1 , wherein the third material comprises an inductively heatable susceptor. 
     
     
         5 . The method according to  claim 4 , wherein the inductively heatable susceptor comprises a plurality of substantially planar inductively heatable susceptor elements and step (b) comprises alternately positioning the plant-based aerosol generating material and the substantially planar inductively heatable susceptor elements in the cylindrical cup. 
     
     
         6 . The method according to  claim 4 , wherein the inductively heatable susceptor is substantially tubular and step (b) comprises positioning the plant-based aerosol generating material and the tubular susceptor in the cylindrical cup so that the plant-based aerosol generating material is arranged both inside and outside the tubular susceptor. 
     
     
         7 . The method according to  claim 4 , wherein the inductively heatable susceptor comprises a particulate susceptor material and step (b) comprises filling the cylindrical cup with a mixture of the plant-based aerosol generating material and the particulate susceptor material. 
     
     
         8 . The method according to  claim 1 , wherein the step of filling the cylindrical cup with the plant-based aerosol generating material and the third material is carried out on a turntable. 
     
     
         9 . The method according to  claim 1 , wherein the method further comprises, after the step of filling the cylindrical cup with the plant-based aerosol generating material and the third material, the step of closing an open end of the cylindrical cup with an air-permeable closure to retain the plant-based aerosol generating material in the cup. 
     
     
         10 . The method according to  claim 1 , wherein the second material includes a filter material. 
     
     
         11 . The method according to  claim 1 , wherein step (ii) comprises arranging two bodies of the second material, one of which constitutes the mouthpiece, in line with the first material so that the first material is positioned between the two bodies of the second material. 
     
     
         12 . The method according to  claim 1 , wherein a hollow body is positioned between the first material and the second material. 
     
     
         13 . The method according to  claim 1 , wherein the method is performed using an apparatus having a plurality of drums and each drum includes a plurality of axially extending and circumferentially arranged grooves which are adapted to perform the arranging of step (ii) or the wrapping of step (iii). 
     
     
         14 . The method according to  claim 1 , wherein the foam material includes an inductively heatable susceptor. 
     
     
         15 . An aerosol generating article comprising:
 a first cylindrical material containing a plant-based aerosol generating material;   a second cylindrical material;   wherein the first cylindrical material and the second cylindrical material are arranged in line and wrapped by a sheet; and   wherein the first cylindrical material comprises a foam material or a cylindrical cup containing plant-based aerosol generating material and a third material.